Advanced Process Control, PID Optimization & Process Engineering Services

Performance drifts. Models lose alignment, constraints widen, and manual intervention increases until instability becomes normal. Atlas works alongside plant operations, inside your existing control systems (DCS, APC, and licensor systems), and stays vendor-neutral. Services begin with a Scan or a focused project and continue as ongoing engineering support as plant conditions change.

The services ladder

Plant Performance Scan

2 to 4 hours, remote, no cost.

Plant Audit

2 to 4 days, onsite, $15,000 flat fee plus travel and living expenses.

Engagement

Restoration, Elevation, or Inception, scoped from the findings.

Sustainment

Remote Resident™, on retainer.

Repeat audit

every 6 to 12 months, reported as a score change.

CLPM pilot

90 days on an agreed set of loops, no cost.

Three starting points

Restoration

Performance has degraded. Atlas finds where alignment was lost and corrects it under real operating conditions to return the unit to a stable baseline.

Elevation

Control is stable but not tight. Atlas tightens precision and reduces variability so the unit can operate closer to its practical limits with confidence.

Inception

Control maturity is limited. Atlas builds the structure required for consistent, controlled performance inside the existing operating environment.

Project Engagements

When performance has degraded and a specific issue needs to be diagnosed and corrected.

Plant engineers and an Atlas engineer reviewing control system performance

Project Engagements

When performance has degraded and a specific issue needs to be diagnosed and corrected.

Remote Resident™

When process control performance must be maintained as conditions change and ongoing fractional engineering expertise is required.

Remote Resident™

When process control performance must be maintained as conditions change and ongoing fractional engineering expertise is required.

Project Engagements

When performance has degraded, focused engineering work is used to diagnose and correct issues directly within the control environment.

1. Start with a specific operating issue

→ isolate where performance has drifted

We begin with a specific operating issue: instability, inefficient transitions, or underperforming control.

The focus is to isolate where performance has drifted and identify the underlying cause.

1. Start with a specific operating issue

→ isolate where performance has drifted

We begin with a specific operating issue: instability, inefficient transitions, or underperforming control.

The focus is to isolate where performance has drifted and identify the underlying cause.

1. Start with a specific operating issue

→ isolate where performance has drifted

We begin with a specific operating issue: instability, inefficient transitions, or underperforming control.

The focus is to isolate where performance has drifted and identify the underlying cause.

2. Diagnose root cause and implement changes

→ execute diagnostics, tuning, and
targeted changes

Diagnostics, model updates, and improvements are carried out directly within the plant’s control systems, working alongside plant engineers in live operation.

This may include APC improvement, loop tuning, CLPM implementation, or developing models and soft sensors where predictive control is not in place.

2. Diagnose root cause and implement changes

→ execute diagnostics, tuning, and
targeted changes

Diagnostics, model updates, and improvements are carried out directly within the plant’s control systems, working alongside plant engineers in live operation.

This may include APC improvement, loop tuning, CLPM implementation, or developing models and soft sensors where predictive control is not in place.

2. Diagnose root cause and implement changes

→ execute diagnostics, tuning, and targeted changes

Diagnostics, model updates, and improvements are carried out directly within the plant’s control systems, working alongside plant engineers in live operation.

This may include APC improvement, loop tuning, CLPM implementation, or developing models and soft sensors where predictive control is not in place.

3. Restore stable performance
in operation

→ results show up in the plant

Changes are reflected directly in plant performance; more stable operation, improved control response, and reduced reliance on manual intervention.

Performance is measured in the unit, under real operating conditions, where the impact is clear and sustained.

3. Restore stable performance
in operation

→ results show up in the plant

Changes are reflected directly in plant performance; more stable operation, improved control response, and reduced reliance on manual intervention.

Performance is measured in the unit, under real operating conditions, where the impact is clear and sustained.

3. Restore stable performance
in operation

→ execute diagnostics,
tuning, and targeted changes

Changes are reflected directly in plant performance; more stable operation, improved control response, and reduced reliance on manual intervention.

Performance is measured in the unit, under real operating conditions, where the impact is clear and sustained.

4. Establish control capability where needed

→ build visibility and foundational models

In environments without advanced control systems, Atlas establishes baseline models, soft sensors, and control strategies to enable stable and measurable performance.

4. Establish control capability where needed

→ build visibility and foundational models

In environments without advanced control systems, Atlas establishes baseline models, soft sensors, and control strategies to enable stable and measurable performance.

4. Establish control capability where needed

→ execute diagnostics,
tuning, and targeted changes

In environments without advanced control systems, Atlas establishes baseline models, soft sensors, and control strategies to enable stable and measurable performance.

When performance issues show up in your plant

These are the signals of performance drift that typically require focused intervention.

Reactor instability

Temperature, pressure, or reactor behavior begins to swing, leading to off-spec production, operating risk, or unstable upstream and downstream conditions.

Inefficient grade transitions

Transitions take longer than expected, with increased off-spec material and difficulty maintaining consistent product quality.

APC underperformance

Controllers move in and out of manual, responses become sluggish or unstable, and performance drifts as plant conditions change.

Fouling and heat transfer

Pressure drop increases and heat transfer becomes less effective, requiring more energy to maintain conditions and limiting process stability.

Discuss your plant with an Engineer

Remote Resident™

Ongoing engineering support to maintain performance as plant conditions change.

Maintain continuous visibility into plant performance

→ monitoring, diagnostics, and performance tracking

Atlas operates as an extension of the engineering team, continuously monitoring plant data, diagnostics, and control behavior.

This creates a shared, ongoing view of performance, as an extension of your team.

Maintain continuous visibility into plant performance

→ monitoring, diagnostics, and performance tracking

Atlas operates as an extension of the engineering team, continuously monitoring plant data, diagnostics, and control behavior.

This creates a shared, ongoing view of performance, as an extension of your team.

Maintain continuous visibility into plant performance

→ monitoring, diagnostics, and performance tracking

Atlas operates as an extension of the engineering team, continuously monitoring plant data, diagnostics, and control behavior.

This creates a shared, ongoing view of performance, as an extension of your team.

Work alongside engineers to diagnose and act

→ model updates and system alignment

Atlas works alongside plant engineers through regular reviews of unit performance, transitions, and control behavior.

Together, we troubleshoot issues, evaluate tuning and system changes, and identify opportunities as conditions evolve.

Work alongside engineers to diagnose and act

→ model updates and system alignment

Atlas works alongside plant engineers through regular reviews of unit performance, transitions, and control behavior.

Together, we troubleshoot issues, evaluate tuning and system changes, and identify opportunities as conditions evolve.

Work alongside engineers to diagnose and act

→ model updates and system alignment

Atlas works alongside plant engineers through regular reviews of unit performance, transitions, and control behavior.

Together, we troubleshoot issues, evaluate tuning and system changes, and identify opportunities as conditions evolve.

Adapt performance as plant conditions change

→ model updates and system alignment

Plant conditions continuously shift due to feed variability, maintenance activities, and operational decisions.

The Remote Resident™ keeps control systems aligned with changing plant conditions through continuous monitoring, adjustment, and engineering support embedded within the plant’s workflow.

Adapt performance as plant conditions change

→ model updates and system alignment

Plant conditions continuously shift due to feed variability, maintenance activities, and operational decisions.

The Remote Resident™ keeps control systems aligned with changing plant conditions through continuous monitoring, adjustment, and engineering support embedded within the plant’s workflow.

Adapt performance as plant conditions change

→ model updates and system alignment

Plant conditions continuously shift due to feed variability, maintenance activities, and operational decisions.

The Remote Resident™ keeps control systems aligned with changing plant conditions through continuous monitoring, adjustment, and engineering support embedded within the plant’s workflow.

As performance drifts over time

These are the signals continuously monitored and corrected to maintain performance in operation:

Frequent operator intervention

Operators regularly moving loops to manual or overriding APC actions to maintain stability.

Performance drift after improvements

Control performance improving after tuning or projects, then gradually drifting back over time.

Changing plant conditions

Feed variability, maintenance activities, and operational changes causing models and tuning to drift out of alignment.

Limited visibility into performance

Lack of continuous monitoring makes it difficult to detect performance drift, instability, or emerging issues early.

Discuss your plant with an Engineer

Services coverage

Services cover APC improvement, PID loop optimization, CLPM, soft sensors, and process engineering support.

01 APC improvement

02 PID loop optimization

03 CLPM

04 Soft sensors

05 Process engineering support

Atlas Advisor™

APC, PID Optimization and Process Engineering Services

Request a Plant Performance Scan Talk with an Engineer